Laminate building materials and methods of making and installing the same

ABSTRACT

Magnesium oxide cement sheathing is laminated to plywood, OSB, wood, steel, other building products or other substrates to enhance fire, structural and sound performance of the substrate to meet new and more stringent fire codes while also providing water, insect, mold and rot protection. Further, the magnesium oxide cement board laminated to a foam core enhances fire performance and mold and rot protection over that of the foam core alone. The magnesium oxide laminate is used in wall, floor and roof assemblies to meet or exceed performance as specified in the building codes.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND

Building departments in the US recognize that increased urban densityelevates the risk of fire spreading to adjacent buildings. In addition,increased development has led to the construction of many buildings inwildfire-urban interface zones. The result is stronger mandates for firecodes that require the use of non-combustible and fire rated materialsin new and retrofit construction. Requirements focus on exterior walls,roofs, and floor structures in various construction applications.

Fire codes focus on flame spread, smoke generation, and duration ofmaterial performance during a fire. The codes determine materialsperformance requirements as well as wall assembly requirements necessaryto meet several classes of construction. Typical wood framed walls androofs utilize plywood or oriented strand board (OSB) as the exteriorsheathing or roofing material. In many applications, codes requirestructure exteriors that are non-combustible.

One response to the fire codes has been to coat wood based sheathingwith an intumescent substance that increases fire performance. Anotherhas been to introduce fire resistant additives in the manufacture of OSBor plywood. Neither of these approached work very well.

Builders sometimes use fire resistant materials, such as gypsum basedsheathing, cementatious siding, and a sufficient thickness of stucco,brick, or stone veneer, in wall and roof assemblies where performance isspecified in the building codes. Such materials are not structural sothey are added in addition to structural sheathing which now must alsobe protected from water penetration behind the fire barrier. These arelayered, costly, and time consuming assemblies.

SUMMARY

Embodiments describe the lamination of Magnesium Oxide (MgO) cementbased boards or sheathing to building materials. In an embodiment, theMgO cement boards are structural and comprise fiberglass-reinforcedmagnesium oxide cement boards. Boards/sheathing made with MgO cement arenoncombustible and generate no smoke when exposed to flame. Unlike OSB,MgO cement boards or sheathing do not support mold or mildew, areinsect-proof, and are water, freeze/thaw, and impact resistant. The MgOcement boards have low thermal conductivity, reflect heat radiation andhelp isolate the wood and other building materials from the heat source.

They can be laminated to wood-based and other products to substantiallyimprove fire performance. Further, the MgO laminate improves the moldand rot protection of the substrate, and eliminates many of the stepsrequired to protect wood or other substrate, which, in turn, reducesbuilding costs. By modifying the chemical mixture, ingredients, andthickness, MgO cement boards can also be engineered to increase thestructural performance of an MgO laminated board. The MgO laminate is anideal solution since the OSB or plywood is already approved forstructural performance under the prescriptive building codes and the MgOprovides the fire performance required to meet new codes.

In another embodiment, the MgO cement boards can be laminated to foammaterials to substantially improve fire, water, rot, and moldperformance. In addition, by using MgO laminated products, many otherbuilding products can be manufactured with the added performance the MgOprovides.

Certain embodiments disclose a building material. The building materialcomprises a magnesium oxide (MgO) board, a substrate, and an adhesivelayer interposed, applied, or located between the MgO board and thesubstrate, where the MgO board is laminated to the substrate with theadhesive layer to form a laminate. In an embodiment, the laminatecomprises a flame spread rating of about zero according to ASTM E-84. Inanother embodiment, the laminate comprises a smoke generation rating ofabout zero according to ASTM E-84. In another embodiment, the laminatehas an airborne sound reduction index of 31 db according to testing doneby the China Building Materials Center for Quality Supervision. In afurther embodiment, the laminate is noncombustible according to ASTME-136. In a yet further embodiment, the building material furthercomprises a finishing material directly applied to the laminate withoutadditional fire or moisture protection, where the finishing materialcomprises stucco, siding, brick, decorative stone, molding and the like.

In an embodiment, the substrate comprises an oriented strand board(OSB), where the laminate comprises a greater resistance to fungalgrowth than the OSB, a greater structural strength than the OSB, agreater resistance to moisture than the OSB. In another embodiment, thesubstrate comprises a foam core material. In a further embodiment, theadhesive layer is selected from the group consisting of polyvinylacetate (PVA), water-based polymeric adhesives, solvent-based adhesives,thermostat adhesives, modified starches, liquid moisture cure adhesives,and polyurethane.

In an embodiment, the substrate comprises a wooden joist including anupper flange, a lower flange, and a web interposed between the upper andthe lower flanges. In another embodiment, the MgO board is laminated toat least one side of the web. In a further embodiment, the MgO board islaminated to both sides of the web. In a yet further embodiment, the MgOboard encases the wooden joist. In an embodiment, the MgO board islaminated to the upper flange and the lower flange along the length ofthe joist. In another embodiment, the joist is a floor and roofingI-joist.

According to some embodiments, a method to fabricate a building materialis disclosed. The method comprises providing a magnesium oxide (MgO)board, providing a substrate, and interposing an adhesive layer betweenthe MgO board and the substrate to laminate the MgO board to thesubstrate with the adhesive layer to form a laminate.

For purposes of summarizing the disclosure, certain aspects, advantagesand novel features of the inventions have been described herein. It isto be understood that not necessarily all such advantages may beachieved in accordance with any particular embodiment of the invention.Thus, the invention may be embodied or carried out in a manner thatachieves or optimizes one advantage or group of advantages as taughtherein without necessarily achieving other advantages as may be taughtor suggested herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a perspective view, partially cut away, of alaminated panel, according to certain embodiments.

FIG. 1B illustrates a cross-sectional view of the laminated panel ofFIG. 1A, according to certain embodiments.

FIG. 2 is a flow chart illustrating a process to manufacture a laminatedbuilding material, according to certain embodiments.

FIG. 3 illustrates a typical wooden joist, according to certainembodiments.

FIG. 4 illustrates a typical wooden I-joist, according to certainembodiments.

FIG. 5 illustrates a laminated fire resistant joist, according tocertain embodiments.

FIG. 6 illustrates a laminated fire resistant I-joist, according tocertain embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The features of the systems and methods will now be described withreference to the drawings summarized above. Throughout the drawings,reference numbers are re-used to indicate correspondence betweenreferenced elements. The drawings, associated descriptions, and specificimplementation are provided to illustrate embodiments of the inventionsand not to limit the scope of the disclosure.

FIG. 1A illustrates a perspective view, partially cut away, of alaminated panel or laminate 100. The laminated panel 100 comprises afirst layer 102 and a second layer or substrate 104. FIG. 1B illustratesa cross-sectional view of the laminate 100 and shows the first layer 102and the second layer 104 may be laminated together using an adhesive 106to create a single piece laminate composite. The laminate 100 can takeany form necessary, including, but not limited to panels, sheets, skins,boards, or the like.

The substrate 104 comprises any of a plurality of building materials,such as, for example, OSB, plywood, wood, steel, metal, foam, foamcores, gypsum based sheathing, and the like. Examples of foam and/orfoam cores are polyurethane, polyester, closed cell polyester, extrudedpolystyrene, ester, latex rubber, neoprene, vinyl, closed cell spongerubber, open cell sponge rubber, cellulose, polystyrene,polyvinylchloride PVC.

In an embodiment, the adhesive 106 comprises a water-based polymericadhesive, such as a latex-based adhesive, or the like. Other examples ofthe adhesive 106 are, but not limited to, polyvinyl acetate (PVA),solvent-based adhesives, thermostat adhesives, natural polymers such asmodified starches, liquid moisture cure or reactive hot melt adhesivessuch as polyurethane, heat or fire resistant adhesives, and the like.

In an embodiment, the first layer 102 comprises Magnesium Oxide (MgO)cement based boards or sheathing. In another embodiment, the MgO cementboards 102 are structural and comprise fiberglass-reinforced MgO cementboards. In a further embodiment, the layer 102 comprises MagBoard™, theproperties of which are described below in Tables A-D. All testing wasdone in accordance to the International Accreditation Service (IAS) ISOGuidelines.

In an embodiment, the thickness of the MgO laminate 100 ranges fromapproximately 9 mm to approximately 42 mm and preferably fromapproximately 12 mm to approximately 24 mm. In an embodiment, thethickness of the first layer 102 ranges from approximately 3 mm toapproximately 18 mm and preferably from approximately 6 mm toapproximately 12 mm. In an embodiment, the thickness of the substrate104 ranges from approximately 3 mm to approximately 24 mm, morepreferably from approximately 6 mm to approximately 18 mm.

Another example of an MgO laminated building product 100 is the MgO/foamlaminate 100 which can be used in the construction of recreationalvehicles (RVs), such as for interior and exterior wall partitions.Typically the RV industry uses a 3 mm wood based plywood productlaminated to extruded polystyrene (XPS) foam, which does not performwell in fires, rots easily, and supports mold. Replacing the wood basedsubstrate with the MgO/foam laminate 100 enhances the long termperformance of the wall partitions and provides enhanced fire, rot,mold, sound and insect resistance over that of the foam alone.

In an embodiment, the MgO/foam laminate comprises MgO cement basedsheathing 102 laminated to a foam core substrate 104. In an embodiment,MgO sheathing 102 is laminated to the foam core 104 using the adhesive106. In some embodiments, the MgO cement based sheathing 102 comprisesMagBoard™ and the foam core 104 comprises extruded polystyrene foam. Ina preferred embodiment, the MgO/foam laminate 100 comprises anapproximately 3 mm thick sheet of MagBoard™ laminated to approximatelyone inch of extruded polystyrene foam. In other embodiments, the MgOboard 102 can be more or less than 3 mm, the substrate 104 can be moreor less than one inch, and the substrate 104 can comprise one or more ofpolyurethane, polyester, closed cell polyester, ester, latex rubber,neoprene, vinyl, closed cell sponge rubber, open cell sponge rubber,cellulose, polystyrene, polyvinylchloride PVC, and the like.

Tests and Test Results

Table A provides the test and performance requirements, the teststandards, the requirements, and the test results for physical propertytesting of approximately 12 mm or ½ inch thick MagBoard™.

TABLE A PHYSICAL PROPERTIES TESTING (12 mm ½ inch) TEST AND PERFORMANCEREQUIREMENTS TEST STANDARD REQUIREMENTS TEST RESULTS Non ASTM E136-09aNo flaming under test Rated as Non Combustible Combustible parametersSurface Burning ASTM E84 5 smoke 10 flame 0 smoke 0 flameCharacteristics contribution contribution Flexural Strength ICC-ES AC386min 580 psi both dry parallel 1576 psi ASTM C1185-08 wet and dry dryperpendicular 2,251 psi wet parallel 1,291 psi, wet perpendicular 2,041psi Freeze Thaw ASTM C666 No disintegration after Pass Cycling 25 CyclesDimension And ASTM C1186 Pass Tolerance Moisture ICC-ES AC386 Accepteddimensional 0.02%, Movement ASTM C1185-08: tolerance from 30 to 90%humidity Water ICC-ES AC386 29.80% Absorption ASTM C1185-08 Water VaporASTM E96/E96M-05 2.46 perms Transmission Compression ICC-ES AC386 >1250psi <.05 inch Pass 1736 PSI Indentation ASTM D2394 Nail Head Pull ICC-ESAC386 >90 lb. 292 lb-pass Through ASTM D1037-99: Lateral Nail ICC-ESAC378 >90 lb. Pass Resistance ASTM D1037-99: ¼″ dry 115 lb, wet 41 lb ⅜″dry 196 lb, wet 113 lb, ½″ dry 261 lb, wet 157 lb, ¾″ dry 337 lb, wet209 lb Falling Ball ICC-ES AC386 no damage at 12″ drop Pass Impact ASTMD1037-99:

Table B provides the test and performance requirements, the teststandards, the requirements, and the test results for assembly and panelstructural testing of approximately 12 mm or ½ inch thick MagBoard.

TABLE B ASSEMBLY and PANEL STRUCTURAL TESTING (12 mm ½ inch) TEST ANDPERFORMANCE REQUIREMENTS TEST STANDARD REQUIREMENTS TEST RESULTSStructural ASTM E72-05 Transverse Load Positive pressure 260 psf 2 × 6WoodFrame (Assembly exceeded test recorded frame capabilities) NegativePressure 210.7 psf Wet Racking Shear 5270 lbs 658.8 plf ⅛ in deflection1483 lbs 185.4 plf Structural ASTM E72-05 Transverse Load, Positivepressure 237 psf 2 × 4 SteelFrame Wet Racking Shear Negative Pressure102 psf 7494 lbs 936.67 plf Structural ASTM E72-02 Ultimate Transverse 0161 psf Insulated panel ASTME564 bearing 4 ft × 8 ft × 6.5 inchAllowable Transverse 0 44.8 psf bearing Ultimate Transverse bearing178.5 psf Allowable Transverse 59.5 psf bearing Ultimate Axial load55,741 lbs Allowable Axial load 4645 lbs Ultimate Shear 10,869 lbsAllowable Shear 453 plf Structural ASTM E72-02 Ultimate Transverse 0185.7 psf Insulated Panel ASTM E564 bearing 4 ft × 8 ft × 8.5 inchAllowable Transverse 0 61.9 psf bearing Ultimate Transverse bearing182.6 psf Allowable transverse bearing 65.7 psf Ultimate Axial load66,246 lbs Allowable Axial load 5,521 lbs Ultimate Shear 10,063 lbsAllowable Shear 377 plf Structural ASTM E72-02 Ultimate Transverse 182psf Insulated Panel ASTM E564 Axial load 43,247 lbs 4 ft × 9 ft × 6.5inch Structural ASTM E72-02 Ultimate Transverse 224 psf Insulated PanelASTM E564 Axial load 51,888 lbs 4 ft × 9 ft × 8.25 inch

Table C provides the test and performance requirements, the teststandards, the requirements, and the test results for assembly and panelfire testing of approximately 12 mm or ½ inch thick MagBoard.

TABLE C ASSEMBLY and PANEL FIRE TESTING (12 mm ½ inch) TEST ANDPERFORMANCE TEST TEST REQUIREMENTS STANDARD REQUIREMENTS RESULTS FireRated E119-08a Per assembly* 2 Hour Fire Assembly Endurance 2 × 6 WoodFrame Rating Fire Rated E119-08a Per assembly* 2 Hour Fire AssemblyEndurance 2 × 4 Steel Frame Rating 6.5 inch Structural E84-10b Perassembly 0 Flame spread Insulated Panel 0 Smoke generation 6.5 inchStructural E119-10a Per assembly* 2 hour fire Insulated Panel endurancerating

Table D provides the test and performance requirements, the teststandards, the requirements, and the test results of wet areaunderlayment and backer board testing of 6 mm or ¼ inch thick MagBoard.

TABLE D WET AREA UNDERLAYMENT AND BACKER BOARD TESTS (6 mm 1/4 inch)TEST AND PERFORMANCE REQUIREMENTS TEST STANDARD REQUIREMENTS TESTRESULTS Dimensional ASTM C1185 Length (in.) =/− .25 Pass TolerancesWidth (in.) =/− .25 Pass Thickness (in.) =/− .25 Pass SquareStraightness (in.) =/− .25 Pass Edge Straightness (in.) =/− .25 PassFlexural Strength ASTM C1185 >1450 PSI 2,854 psi Fastener Pull ASTMD1037 >.90 Pass Through Compressive ASTM C1325 >1250 PSI Pass StrengthASTM D3295 Surface Burning ASTM E84 5 smoke 10 flame 0 smoke 0 flameCharacteristics contribution contribution Non Combustible ASTM E136-09aNo flaming under test Rated as Non Combustible parameters Mold andMildew ASTM G21 Non Nutrient Pass Non Nutrient ASTM D3273 Fungus TestingASTM D3273 Pass No evidence of fungal growth ASTM rating of 10 LinearVariation ASTM D1037 Less than or equal to .07% 0.07% With Change InMoisture Content Moisture ASTM C1185 Less than or equal to .02% 0.07%Movement % Linear Change Modulus of ASTM D1037 398,900 psi 456,100 psiElasticity ANSI 208.1-99 Modulus of ASTM D1037 2,393 psi 3,071 psiRupture ANSI 208.1-99 Modulus of ASTM D1037 retain min of 50% MOR PassRupture Retention ANSI 208.1-99 Weight ASTM 1037 Weight per Sq. Ft. 1.4lbs. Thickness Swell ASTM 1037 24 hour thickness swell 3.5%-4% 7 dayShear Bond ANSI A 118.1 50 PSI at 7 day curing 98 psi Strength PortlandCement 7 Day Shear Bond ANSI 136.1 50 PSI at 7 day curing 189 psiStrength Organic Mortar Latex Portland ANSI A 118.4 50 PSI at 7 daycuring 201 psi Cement Mortar Organic Mortar ANSI 136.1 50 PSI at 7 daycuring Pass Humidified ICC-ES AC386 <.3125 in. (ceiling) .053 in.Deflection ICC-ES AC378 ASTM C473-07:

Table E provides the test and performance requirements, the teststandards, the requirements, and the test results of sound testing of 12mm or ½ inch thick MagBoard™ according to testing done by the ChinaBuilding Materials Center for Quality Supervision.

Fire and Combustibility Testing

Of particular note are the results of the fire performance testing. Whenevaluating building materials for fire safety, many factors includingignition temperature, smoke toxicity and flame-spread are considered.Flame-and smoke spread and combustibility, used to describe the surfaceburning characteristics of building materials, are among the most testedfire performance properties of a material. The best known test fordeveloping a flame and smoke spread rating is the American Society forTesting and Materials (ASTM) Test Method E-84, commonly known as thetunnel test. The tunnel test measures how far and how fast flames spreadacross the surface of the test sample. In this test, a sample of thematerial 20 inches wide and 25 feet long, is installed as ceiling of atest chamber, and exposed to a gas flame at one end. The resulting flamespread rating (FSR) is expressed as a number on a continuous scale whereinorganic reinforced cement board is 0 and red oak is 100. The scale isdivided into three classes. The most commonly used flame-spreadclassifications are: Class I or A, with a 0-25 FSR; Class II or B with a26-75 FSR; and Class III or C with a 76-200 FSR.

Table A includes the ASTM E-84 test results for 12 mm MagBoard™; Table Cincludes the ASTM E-84 test results for a 6.5 inch Structural InsulatedPanel of 12 mm MagBoard™; and Table D includes ASTM E-84 test resultsfor 6 mm MagBoard™. In each case, MagBoard™ has a flame spread rating ofapproximately zero, has a smoke generation rating of approximately zero,and is a Class A material.

In contrast, OSB has a flame spread rating of approximately 148 and asmoke generation rating of approximately 137, and is a Class C material.Since the ASTM E-84 test is a surface burning test, the laminate 100would have the same or similar test results as the MagBoard testresults. Thus, the MgO/OSB laminate 100 has significantly improvedsurface burning and smoke generation characteristics to that of the OSBsubstrate 104.

The best known test for combustibility is the American Society forTesting and Materials (ASTM) Test Method E-136. The ASTM E-136 testmeasures the behavior of materials in a vertical tube furnace at 750° C.Table D includes the ASTM E-136-09a test results for 6 mm MagBoard. Thetest results indicate no flaming under the test parameters and theMagBoard is rated as non-combustible.

In contrast, OSB is combustible. Even with cementatious or other fireretardant coatings, OSB is not rated as non-combustible. Thus, theMgO/OSB laminate 100 has significantly improved non-combustibilitycharacteristics to that of the OSB substrate 104.

The ASTM E-119 test measures the hourly fire resistance rating for anassembly using construction materials. An hourly fire rating is the timea wall assembly can be expected to contain a fire and, in the case ofload-bearing walls, continue to provide some structural support. Thistest is not a requirement for a material to be used in non-combustibleconstruction, but can be a requirement based on the construction andoccupancy types for the building. Table C includes the ASTM E-119-08atest results for a 2×6 wood frame assembly constructed withapproximately 12 mm MagBoard and a 2×4 steel frame assembly constructedwith approximately 12 mm MagBoard. Table C further includes the ASTME-119-10a test results for a 6.5 inch structural insulated panel (SIP)constructed with approximately 12 mm MagBoard. In each test, theMagBoard assembly achieved at least a 2 hour fire endurance rating.

In contrast, a partition wall assembly constructed with 15 mm OSB has afire rating of approximately 14 minutes. Thus, the MgO/OSB laminate 100has significantly improved fire rating characteristics to that of theOSB substrate 104.

Thus, by laminating Magboard 102 to a substrate 104, the fireperformance of a wall assembly can be greatly improved. Further, byvarying the thickness of the Magboard layer 102, the laminate 100 can bemanufactured to have a range of fire performances, including flamespread, combustibility, and fire rating, to meet current and futurebuilding codes. Building products and or assemblies laminated with theMgO layer 102 can be manufactured to have a range of fire performances,including flame spread, combustibility, and fire rating, to meet currentand future building codes.

Mold/Rot Testing

ASTM D3273 tests for the resistance to growth of mold on the surfaceinterior coatings in an environmental chamber and ASTM G21 determinesthe effect of fungi on the properties of the tested material. Asindicated in Table D, MagBoard is a non-nutrient for mold and mildewaccording to ASTM G21 and ASTM D3272 testing. Further, there is noevidence of fungal growth according ASTM D3273 testing. MagBoard has anASTM D3273 rating of 10, indicating no disfigurement by particulatematter.

In contrast, structural wood products, such as OSB, lumber, plywood, andthe like, share the same basic chemical composition, namely a matrix ofcellulose and lignin, which support fungi, mold and mildew growth. Oftenantifungal agents are applied to OSB to reduce the risk of toxic moldgrowth. Further, during construction of buildings, additional layers areadded to protect OSB and other wood products from moisture, a majorcause of mold growth. This adds additional construction costs.

The MgO board layer 102 provides fungi, mold, and mildew resistancewhich is the same as or similar to the MagBoard ASTM G21 and D3273 testresults to the laminate 100. Thus, the MgO/OSB laminate 100 hassignificantly improved fungi, mold, and mildew resistancecharacteristics to those of the OSB substrate 104 alone.

Structural Testing

ASTM E72-05 tests the strength of panels for building construction.Table B indicates the ASTM E72-05 test results for assemblies and panelscomprising 12 mm MagBoard. The MagBoard assembly and panel test resultsare consistent with the ASTM E72-05 test results for OBS, SIPs, or otherbuilding material assemblies and panels.

Sound Testing

The Airborne Sound Reduction Index is used to measure the level of soundinsulation provided by a structure such as a wall, window, door, orventilator. This is a laboratory measurement, which uses knowledge ofthe relative sizes of the rooms in the test suite, and the reverberationtime in the receiving room, and the known level of noise which can passbetween the rooms in the suite by other routes (flanking) plus the sizeof the test sample to produce a very accurate and repeatable measurementof the performance of the sampled material or construction. Table Eindicates the Airborne Sound Reduction Index for 12 mm Magboard™ isapproximately 31 dB. Thus by laminating Magboard™ to the substrate 104,an improvement in the sound performance of wall assemblies can beachieved.

Vapor Retardant

Moisture or water vapor can move into building cavities in three ways:with air currents; by diffusion through materials; and by heat transfer.Of these three, air movement typically accounts for more than 98% of allwater vapor movement in building cavities. Material that slow the rateof vapor diffusion into the thermal envelope of a structure, such as thewall, ceiling, and floor assemblies of buildings are referred to asvapor retarders. Vapor retarders have varying degrees of permeabilityand have a moisture vapor transmission rate that is established bystandard test methods. Permeability can be reported in perms, a measureof the rate of transfer of water vapor through a material where 1.0 USperm=1.0 grain/square-foot•hour•inch of mercury ≈57 SI perm=57ng/s•m2•Pa.

Adhesives act as vapor retarders and each adhesive has a different vaporretardant property. In certain embodiments, the adhesive 106 in thelaminate 100 is a vapor retarder. The laminate 100 comprising theadhesive 106 comprises a structural vapor diffusion retarder, whichretards the diffusion of water vapor or other moisture through wall,ceilings and floor assemblies of buildings, as well as having otherstructural and fire resistant properties. [0049] Building codes changeoften, and typically become stricter to enhance safety and performanceof the building project. Advantageously, the MgO laminate 100 can meetor out perform these performance requirements. For example, thethickness of the MgO board 102 and/or the thickness and/or material ofthe substrate 104 can be varied to meet ever increasing designrequirements or changing building codes. In another example, theadhesive 106 used in fabricating the laminate 100 can be varied toprovide laminates 100 that meet varying permeances of vapor retardsspecified in the building codes.

FIG. 2 is a flow chart illustrating a process 200 to manufacture alaminated building material, such as the laminate 100. At step 202, theprocess 200 provides sheathing, such as the MgO cement based sheathing102 and at step 202 the process 200 provides the substrate 104.

At step 206, the adhesive 106 is applied. In an embodiment, aroller-coater process applies the adhesive. Other methods of applyingthe adhesive 106 comprise rolling by hand, painting, spraying, and thelike. The adhesive is preferably applied evenly over the surface. Thewet film weight of the applied adhesive 106 when measured with astandard scale ranges from approximately 22 grams per square foot toapproximately 30 grams per square foot, and preferably is not less thanapproximately 26 grams per square foot and not more than approximately30 grams per square foot. In an embodiment, the adhesive 106 is appliedto the top layer 102. In another embodiment, the adhesive 106 is appliedto the substrate 104. The layer 102, 104 without the adhesive 106 isplaced on top of the layer 102, 104 coated with the adhesive 106.

In another embodiment, at step 206, the process 200 uses a roll presslamination process with a suitable pressure sensitive adhesive tolaminate the top layer 102 to the substrate 104.

At step 208, the process 200 cures the laminate under pressure. In anembodiment, the laminate 100 is place in a press and cured under apressure of approximately 10 psi to approximately 14 psi, and preferablyapproximately 12 psi. In one embodiment, the adhesive 106 comprises alatex-based adhesive and the curing time ranges from about 20 minutes toabout 30 minutes. In addition, the curing time may vary with thetemperature of the curing environment, such that less time may needed tocure the laminate 100 when it is hot, and more time may be needed whenit is cool. In other embodiments, other adhesives 106 are used, and thecuring time varies based on the adhesive and the temperature.

At step 210, the process 200 optionally applies a finish to the laminate100. For example, the edges of the laminate 100 could be sealed torestrict water absorption by painting the edges with paint or othersealer, the surface of the laminate 100 could be painted, covered withstucco, or the like, a wood grain or other texture could be formed inthe laminate 100 or formed during the fabrication of the MgO board 102,another layer, such as a wood layer with a wood grain finish could belaminated to the laminate 100, and the like. The finishing step 210 canbe performed during the fabrication of the laminate 100, at aconstructions site, or at any other time.

Installation

The laminate 100 may be installed on interior or exterior walls. Thelaminate can be installed using a compatible adhesive, mechanicalfasteners, such as screws, nails, and the like, or a combination. Thelaminate 100 may be applied to wood or steel framing.

Building Product Embodiments

In addition, by using MgO laminated products, many other buildingproducts can be made with the added performance of the MgO layer 102.One example of an MgO laminated building product is a laminated fireresistant joist. FIG. 3 illustrates typical framing construction 300comprising traditional wooden joists 302. In an embodiment, the joists302 comprise timber, plywood, OSB, and the like. The joists 302 aboveone or more studs are being used as roofing joists and the joists 302below a floor 306 are being used as flooring joists, in the illustratedexample in FIG. 3.

FIG. 4 illustrates a typical wooden I-joist 400 comprising a web orvertical element 404 inserted in the grooves of upper and lower flangesor horizontal elements 402 a, 402 b, respectively. In an embodiment, thejoist 400 comprises a Truss Joist I-beam™ (™). In an embodiment, theflanges 402 and the web 404 comprise wood, plywood, OSB, and the like.

FIG. 5 illustrates a laminated fire resistant joist 500 comprising thejoist 300 laminated with MgO cement based boards 502, 504, 506, 508,510. In the illustrated embodiment, MgO board 502 is laminated to afirst side of the joist 300; MgO board 504 is laminated to a second sideof the joist 300; MgO board 506 is laminated to a third or top side ofthe joist 300, MgO board 508 is laminated to a fourth or bottom side ofthe joist 300; MgO board 510 is laminated to a first end of the joist300; and MgO board 512 is laminated to a second end of the joist 300. Inan embodiment, the MgO boards 502-512 encompass, surround, enclose,encase or envelop the joist 300.

In an embodiment, boards 502-512 comprise Magnesium Oxide (MgO) cementbased boards or sheathing. In another embodiment, the MgO cement boards502-512 are structural and comprise fiberglass-reinforced MgO cementboards. In a further embodiment, the boards 502-512 comprise MagBoard™.

In an embodiment, the fire resistant joist 500 is a fire resistant floorand roof joist. The joist 500 encases the wooden joist 300 and providesthe fire, insect, mold, mildew, and rot protection associated with theMgO boards.

FIG. 6 illustrates a laminated fire resistant joist 600. The joist 600comprises the joist 400 laminated with MgO cement based boards. In theillustrated embodiment, an upper surface of the upper flange 402 a and alower surface of the lower flange 402 b are laminated with the MgOcement based boards 602 a, 602 b, respectively, and the first and secondsides of the web 404 are laminated with the MgO cement based boards 604a, 604 b, respectively. In a further embodiment, the front end and theback end of the joist 400 are laminated with MgO boards cement basedboards 606 a and 606 b (not illustrated), respectively. In anembodiment, the MgO boards 602-606 encompass, surround, enclose, encase,or envelop the joist 400.

In an embodiment, boards 602-606 comprise Magnesium Oxide (MgO) cementbased boards or sheathing. In another embodiment, the MgO cement boards602-606 are structural and comprise fiberglass-reinforced MgO cementboards. In a further embodiment, the boards 602-606 comprise MagBoard™.

Laminated joists 500, 600 comprise similar flame spread and smokegeneration numbers as those for MagBoard included on Tables A, C, and D.As discussed above, the flame spread for the laminated joist 500, 600 isapproximately zero and the smoke generation number is approximatelyzero. Similarly, floor and roofing joists made of unprotected OSBcomprise similar flame spread and smoke generation numbers as standardOSB, such as a flame spread rating of approximately 148 and a smokegeneration rating of approximately 137.

Thus, the laminated joist 500, 600 has substantially increased the flameresistance and smoke spread characteristics of joists constructed of OSBor a similar material alone. The resulting laminated joist 500, 600comprises a fire resistant joist having the enhanced fire and structuralperformance associated with the MgO cement board to meet new and morestringent fire codes, while also providing water, insect, and mold androt protection.

While specific embodiments of, and examples for, the invention aredescribed above for illustrative purposes, various equivalentmodifications are possible within the scope of the invention, as thoseordinary skilled in the relevant art will recognize. For example, othersubstrates, such as metal, foam, fiberglass reinforced plastic, plywoodand the like, can be laminated to magnesium oxide boards to provide thelaminate with enhanced characteristics provided by the magnesium oxideboard. In another example, other OSB or wood building products, such asmelamine, particle board, high density chip board, and the like can belaminated with magnesium oxide board to enhance the laminated productswith the characteristics of the magnesium oxide board.

Terminology

The above detailed description of certain embodiments is not intended tobe exhaustive or to limit the invention to the precise form disclosedabove. While specific embodiments of, and examples for, the inventionare described above for illustrative purposes, various equivalentmodifications are possible within the scope of the invention, as thoseordinary skilled in the relevant art will recognize. For example, whileprocesses or blocks are presented in a given order, alternativeembodiments may perform routines having steps, or employ systems havingblocks, in a different order, and some processes or blocks may bedeleted, moved, added, subdivided, combined, and/or modified. Each ofthese processes or blocks may be implemented in a variety of differentways. Also, while processes or blocks are at times shown as beingperformed in series, these processes or blocks may instead be performedin parallel, or may be performed at different times.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise,” “comprising,” and thelike are to be construed in an inclusive sense, as opposed to anexclusive or exhaustive sense; that is to say, in the sense of“including, but not limited to.” The words “proportional to”, asgenerally used herein refer to being based at least in part on. Thewords “coupled” or connected”, as generally used herein, refer to two ormore elements that may be either directly connected, or connected by wayof one or more intermediate elements. Additionally, the words “herein,”“above,” “below,” and words of similar import, when used in thisapplication, shall refer to this application as a whole and not to anyparticular portions of this application. Where the context permits,words in the above Detailed Description using the singular or pluralnumber may also include the plural or singular number respectively. Theword “or” in reference to a list of two or more items, that word coversall of the following interpretations of the word: any of the items inthe list, all of the items in the list, and any combination of the itemsin the list.

Moreover, conditional language used herein, such as, among others,“can,” “could,” “might,” “may,” “e.g.,” “for example,” “such as” and thelike, unless specifically stated otherwise, or otherwise understoodwithin the context as used, is generally intended to convey that certainembodiments include, while other embodiments do not include, certainfeatures, elements and/or states. Thus, such conditional language is notgenerally intended to imply that features, elements and/or states are inany way required for one or more embodiments or that one or moreembodiments necessarily include logic for deciding, with or withoutauthor input or prompting, whether these features, elements and/orstates are included or are to be performed in any particular embodiment.

The teachings of the invention provided herein can be applied to othersystems, not necessarily the systems described above. The elements andacts of the various embodiments described above can be combined toprovide further embodiments.

While certain embodiments of the inventions have been described, theseembodiments have been presented by way of example only, and are notintended to limit the scope of the disclosure. Indeed, the novel methodsand systems described herein may be embodied in a variety of otherforms; furthermore, various omissions, substitutions and changes in theform of the methods and systems described herein may be made withoutdeparting from the spirit of the disclosure. The accompanying claims andtheir equivalents are intended to cover such forms or modifications aswould fall within the scope and spirit of the disclosure.

What is claimed is:
 1. A building material comprising: a magnesium oxide(MgO) board; a substrate; and an adhesive layer interposed between theMgO board and the substrate, the MgO board laminated to the substratewith the adhesive layer to form a laminate.
 2. The building material ofclaim 1 wherein the laminate comprises a flame spread rating of aboutzero according to ASTM E-84.
 3. The building material of claim 1 whereinthe laminate comprises a smoke generation rating of about zero accordingto ASTM E-84.
 4. The building material of claim 1 wherein the laminateis noncombustible according to ASTM E-136.
 5. The building material ofclaim 1 further comprising a finishing material directly applied to thelaminate without additional fire or moisture protection.
 6. The buildingmaterial of claim 1 wherein the substrate comprises an oriented strandboard (OSB).
 7. The building material of claim 6 wherein the laminatecomprises at least one of a greater resistance to fungal growth than theOSB, a greater structural strength than the OSB, and a greaterresistance to moisture than the OSB.
 8. The building material of claim 1wherein the substrate comprises a foam core material.
 9. The buildingmaterial of claim 1 wherein the adhesive layer is selected from thegroup consisting of polyvinyl acetate (PVA), water-based polymericadhesives, solvent-based adhesives, thermostat adhesives, modifiedstarches, liquid moisture cure adhesives, and polyurethane.
 10. Thebuilding material of claim 1 wherein the adhesive layer is associatedwith a permeability and the laminate comprises a structural vapordiffusion retarder.
 11. The building material of claim 1 wherein thesubstrate comprises a joist including an upper flange, a lower flange,and a web interposed between the upper and the lower flanges.
 12. Thebuilding material of claim 11 wherein the MgO board is laminated to atleast one side of the web.
 13. The building material of claim 11 whereinthe MgO board is laminated to both sides of the web.
 14. The buildingmaterial of claim 11 wherein the MgO board is laminated to the upperflange and the lower flange along the length of the joist.
 15. Thebuilding material of claim 11 wherein the MgO board encases the joist.16. The building material of claim 1 wherein the MgO board forms atleast one surface of a laminate to increase the fire rating of a wallassembly.
 17. A method to fabricate a building material, the methodcomprising: providing a magnesium oxide (MgO) board; providing asubstrate; and interposing an adhesive layer between the MgO board andthe substrate to laminate the MgO board to the substrate with theadhesive layer to form a laminate.
 18. The method of claim 17 whereinthe laminate comprises a flame spread rating of about zero according toASTM E-84.
 19. The method of claim 17 wherein the laminate comprises asmoke generation rating of about zero according to ASTM E-84.
 20. Themethod of claim 17 wherein the laminate is noncombustible according toASTM E-136.
 21. The method of claim 17 further comprising a finishingmaterial directly applied to the laminate without additional fire ormoisture protection.
 22. The method of claim 17 wherein the substratecomprises an oriented strand board (OSB).
 23. The method of claim 22wherein the laminate comprises at least one of a greater resistance tofungal growth than the OSB, a greater structural strength than the OSB,and a greater resistance to moisture than the OSB.
 24. The method ofclaim 17 wherein the substrate comprises a foam core material.
 25. Themethod of claim 17 wherein the adhesive layer is selected from the groupconsisting of polyvinyl acetate (PVA), water-based polymeric adhesives,solvent-based adhesives, thermostat adhesives, modified starches, liquidmoisture cure adhesives, and polyurethane.
 26. The method of claim 17wherein the substrate comprises a joist including an upper flange, alower flange, and a web interposed between the upper and the lowerflanges.
 27. The method of claim 26 wherein the MgO board is laminatedto at least one side of the web.
 28. The method of claim 26 wherein theMgO board is laminated to both sides of the web.
 29. The method of claim26 wherein the MgO board is laminated to the upper flange and the lowerflange along the length of the joist.
 30. The method of claim 26 whereinthe MgO board encases the joist.